Artur Sadzik, Project Industry 4.0 Manager, APA Group
The Fourth Generation Industry is a relevant response to the complex problems of the contemporary world. By the same token, it is an idea that must be implemented If you want to focus on progress in modern business. To this end, NAZCA 4.0 is providing support in developing such an approach at the plant.
Industry 4.0. is a concept that originated at the beginning of the 21st century and is relatively recent. Since its inception, it has been based on the use of modern technologies, led by the Industrial Internet of Things (IioT) and Big Data. The former combines information technology with operational technology, and refers to the networking of processes and industrial ICS control systems.
One significant thread related to Industry 4.0 is the context of production management, organizational operations and the value creation chain. There is a change in the architectures of production management systems and a shift from linear processes and the traditional pyramid of management systems to non-linear production, and a new network of connections. Consequently, the ways in which manufacturing is administered are changing, as from now on, systems are running fully or partially automatically .
In summary, automation and computerization are the core of the new approach to manufacturing processes and customer service, using the Internet of Things (IoT) and intelligent systems based on computer algorithms, which are applied to monitor and control elements of the physical environment. These include machines, robots and vehicles.
Industry in a tighter spot than before
In the case of the industrial sector, referring to pre-2020 data does not make much sense. Experts believe that the sector has slowed down considerably.
In May 2022 alone, the sold production of Polish industry recorded the steepest decline since the similar spring period two years earlier. Meanwhile, S&P Global reported that this year’s manufacturing PMI for Poland in June was 44.4 points, compared to 48.5 points in May. This is the lowest value over 25 months.
The solution? For example, modifying existing planning, manufacturing and monitoring habits. Piotr Arak, head of the Polish Economic Institute, puts it this way about the potential scenario: We’ re in for a “small revolution.” We will be shifting more emphasis to strategic resilience – energy sovereignty and access to cutting-edge technologies (…). The specialist thus referred to the situation in various sectors, not just industry.
The future lies in Industry 4.0
Industry 4.0 will triumph in global markets in the forthcoming years. By 2028, the demand for solutions in this area is expected to reach $334.18 billion, representing an estimated increase of $250 billion compared to 2020.
→ You can read more about this HERE.
The future definitely belongs to the digital- based approach. We can already see predictive models supporting the thesis that implementing from 3.0 to 4.0 is not only feasible, but also profitable.The new approach to doing business must include the implementation of the Internet of Things (IoT) in the production process, as well as data analysis in terms of production planning and optimization.
What can be gained with a new approach and what can be lost when new technologies are not implemented
According to Ubisense’s “Smart Manufacturing Technologies” survey of manufacturers, more than 40% of respondents have no insight into real-time data on manufacturing processes, while 8 out of 10 companies rely entirely on simple human observation when improving processes, without using modern technologies. One more significant finding of the survey is that nearly 10% of respondents spend up to half of their working day only searching for products and equipment.
Meanwhile, all this eventually has a knock-on effect on production, in the short and long term. The more outdated the working and evaluation methods are, the more likely the plant will operate inefficiently and ultimately fail to withstand the market pressure.
It is totally different when taking on board the principles of Industry 4.0. By implementing a digitization-based approach and creating a so-called smart factory, you can:
- optimize production costs (due to identification of losses and cost monitoring),
- improve management (data aggregated in one coherent system can be easily analyzed and relevant decisions can be made on their basis),
- level out possible downtime (you get immediate information about so-called bottlenecks in the process),
- reduce production costs while increasing efficiency and streamlining logistics,
- increase production flexibility (which involves changing the way people work and their role in the industry),
- test new business models and seize opportunities in a timely manner,
- produce even high-end products that offer the ability to track (RFID tags) the entire life cycle – from production, to transportation, to maintenance and to recycling.
AZCA 4.0, a response to modern industry
Modern and thoughtful tools such as NAZCA 4.0 from APA Group perfectly match the needs of Industry 4.0.
It is a versatile technology to automate the information flow management, which besides the functionalities of Industry 4.0, within a single platform, delivers solutions for the following classes:
- BMS (Building Management System) – control of technical functions of a building, especially in a smart building. The task of BMS automation is to integrate the installations existing in the facilities.
- SMS (Smart Manufacturing Systems) – are used to integrate various technologies such as automation, data exchange, cyber-physical systems (CPS), artificial intelligence, Internet of Things (IoT) and semi-autonomous industrial systems.
- EMS (Electronics Manufacturing Services) – contract manufacturing which involves companies that design, distribute and provide return/repair services of electronic components for OEMs.
Its distinguishing features include:
- Scalability: multi-server architecture of the system enables building a distributed system.
- Clear interface: readable, responsive and customized visualization, allows for quick analysis of large data sets, finding regularities and specific areas to optimize.
- Versatility: the universal and all-round nature of NAZCA allows the system to be used in industrial solutions, large-scale buildings and warehouses, as well as commercial facilities.
Technologies leveraged by NAZCA 4.0
- Big Data analytics
- Mobile interfaces
- Additive printing
- Cloud computing
- Collaborative robots
- System integration
- Advanced interface
- Process simulation
- Virtual reality
- Intelligent sensors
- Predictive maintenance
- System diagnostics
NAZCA’s capabilities in the context of Industry 4.0
NAZCA 4.0 is a tool that aligns with the needs of today’s industry in various areas.
Here are some of the software capabilities from APA.
- Streamlining the data stream and facilitating strategic decision-making. NAZCA 4.0 allows you to fish out of the stream of transmitted information only the most relevant from the user’s standpoint and the devices as such.
- Detecting defects even before they occur (predictive maintenance). Predictive maintenance includes such end-to-end in-plant operations as evaluating performance data, replenishing lubricants, replacing parts and documenting wear and tear.
- Streamlining logistics and shortening the supply chain. Big Data Analytics using NAZCA 4.0 allows you to see and examine when a driver’s work is most effective: on which route, at which times and under which conditions.
- Strengthening your company’s digital security. The tool described here provides full functionality for Industry 4.0, from advanced data analytics to asset protection against cyber attacks.
So if you’re looking for a modern and all-in-one application designed to integrate Production Management Systems 4.0, NAZCA 4.0 is exactly up to the task.
Do you want to learn more about implementing the Fourth Generation Industry with NAZCA 4.0?
Download the full whitepaper we have compiled.